Attachment J.1 - Fac 738 OOS Final Report 2010.pdf

CONTRACT FA5000-10-D-0024, DO 1

TANK 738 (FACILITY 18471)

API 653 TANK INSPECTION AND

SUITABILITY FOR SERVICE EVALUATION

(PRE-REPAIR)

Elmendorf AFB, Alaska

September 2010

Prepared For:

Air Force Civil Engineering Support Agency 139 Barnes Drive, Suite 1 Tyndall AFB, Florida 32403-5319

Presented By:

Winsor Construction, Inc.

14939 W. Lake Ridge Drive Eagle River, Alaska 99577

Prepared By:

Ali M. Martinez, P.E., API 653 Certificate No. 28604

Submitted By:

Stephen S. Brooks, P.E.

Principal, API 653 Certificate No. 17 2525 Gambell Street, Suite 200, Anchorage, AK 99503

EEI PROJECT 10-5579

ABSTRACT

Enterprise Engineering, Inc. (EEI) has completed a comprehensive, out-of-service internal and external inspection and suitability for service evaluation of Tank 738 (Facility 18471) at Elmendorf Air Force Base. The inspection was performed in accordance with the applicable criteria of API Standard 653, UFC 3-460-01and the Statement of Work. The API 653 criteria were followed in terms of procedure and evaluation to the greatest extent possible. The inspection was performed on August 17 and 18, 2010.

This report provides inspection findings, tank suitability for service evaluation, conclusions, and recommendations for repair, prior to returning the tank to service. Recommendations for continued long-term service are also provided.

EEI recommends that the next API external in-service inspection be scheduled no later than August 2015 (5 years from 2010 inspection), or sooner if a change in condition has occurred.

EEI recommends the next API internal out-of-service inspection be scheduled no later than September 2025 (15 years from 2010 inspection), or sooner if a change in condition has occurred.

In accordance with API Standard 653, this report satisfies the requirement for an out-of-service, integrity inspection and as such, should remain available as a historical record for future reference.

I hereby acknowledge that being familiar with the provisions of API Standard 653, the inspection and evaluation was performed in accordance with the provisions of API Standard 653 and good engineering practices, and with the exercise of usual and customary care.

September 3, 2010 Ali M. Martinez, P.E. Date API 653 AST Inspector Certificate No. 28604

This inspection has determined that mandatory repairs are not required prior to return to service. Tank 738 may be returned to service. Recommended repairs have been identified, and if possible should be completed before returning tank to service.

Tank 738 - API 653 Inspection TABLE OF CONTENTS Elmendorf AFB, Alaska September 2010 EEI Project No.: 10-5579

TABLE OF CONTENTS

Page

SUMMARY

Scope General

INSPECTION ASSESSMENT

Hydraulic Integrity Structural Integrity Next Inspection

REPAIR ITEMS

Standard of Care Required Repairs Prior to Return to Service (Mandatory) Recommended Repairs Prior to Return to Service (Non-Mandatory) Recommended Repairs per Current Military Criteria:

Recommended Repairs for Long Term Serviceability

COATING REQUIREMENTS

Coating System at Localized Repair Locations (Interior and Exterior)

SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates Tank Floor Corrosion Rates Hydraulic and Structural Integrity

ADDITIONAL DISCUSSION ITEMS

Gauge Tube Requirements Tank 738 Existing Conditions Gauge Tube Recommendation

CLOSURE

Conclusions Project Team

APPENDICES

Tank Inspection Data Sheet and Evaluation Items ................................................... Tab A

Non-Destructive Examination (NDE) and Evaluation Criteria ................................... Tab B

Tank Drawings ........................................................................................................ Tab C

Tank Photographs ................................................................................................... Tab D

NDE Results ............................................................................................................. Tab E

Calculations .............................................................................................................. Tab F

Field Inspection Report ........................................................................................... Tab G

Tank 738 – API 653 Inspection Page 1

EEI Project No.: 10-5579

TANK 738

(FACILITY 18471)

API 653 TANK INSPECTION

SUITABILITY FOR SERVICE EVALUATION

ELMENDORF AFB, ALASKA

SUMMARY

Scope

Enterprise Engineering, Inc. (EEI) has completed a comprehensive out-of-service inspection and suitability for service evaluation of Tank 738 at Elmendorf AFB, Alaska. The inspection was performed August 17 and 18, 2010, in accordance with the applicable criteria of API Standard 653 and UFC 3-460-01. The API 653 criteria were followed in terms of procedure and evaluation to the greatest extent possible.

The scope of this project is to determine the structural and hydraulic condition of the tank, determine suitability for service, provide written recommendations for repairs, and develop recommendations for long-term service based on visual inspection and non-destructive examination (NDE).

General

Tank 738 is a field erected aboveground storage tank. The tank was fabricated and erected in 1998. The tank is 112 feet in diameter and 51 feet 6 inches high and is of welded construction with butt-welded shell plates and lap welded roof and floor plates. The nominal shell capacity is 80,000 Bbls. Tank 738 is equipped with a floating pan and is currently in JP-8 service.

INSPECTION ASSESSMENT

The Appendices in this report includes a comprehensive table identifying tank features with findings and conclusions as appropriate. The Appendices also contain numerous tables with full reporting of the data taken. The following discussion only addresses key integrity issues.

Tank 738 is considered suitable for service as no mandatory repairs were identified. The following are significant findings of the inspection.

Hydraulic Integrity

Hydraulic integrity is the ability of the tank to hold product without compromise to the boundaries of the floor and shell.

A magnetic flux leakage (MFL) scan of the tank floor found no relevant indications of corrosion on the bottom side of the floor requiring repair. A pit survey was conducted for topside corrosion and no pits were identified requiring repair.

Based on this inspection, Tank 738 is in acceptable hydraulic condition.

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EEI Project No.: 10-5579

Structural Integrity

Structural integrity is the capability of the tank to remain freestanding, with or without product, under the conditions of its design basis. Structural attributes include the floor, shell, roof, and their attachments. Ultrasonic inspections of the shell were performed on the first course and on each course from the exterior spiral stair. From interpretation of ultrasonic test (UT) readings recorded, only plate thickness variances were noticed.

Based on this inspection of the accessible components, Tank 738 is in acceptable structural condition.

Next Inspection

Alaska Department of Environmental Conservation (ADEC) requires an inspection of regulated tanks for structural integrity at least every ten years unless a shorter or longer inspection interval is prescribed by API 653. API 653 recommends the interval to the next internal inspection be determined based on known corrosion rates, but in no case shall the interval exceed 20 years.

When corrosion rates are not known or well established, API 653 recommends that the tank be inspected within 10 years. A maximum interval between inspections of 10 years is also commonly used in many government and commercial facilities.

ADEC may reduce the inspection interval for a specific storage tank if

(a) The storage tank is older than 30 years,

(b) The storage tank is of riveted or bolted construction,

(c) The storage tank has demonstrated structural, corrosion or foundation problems, or

(d) After a significant seismic event.

Based on the corrosion rate calculation, the useful life of the tank floor would appear to be 15 years. Although this appears limiting, the young age of the tank (12 years) skews the corrosion calculations. In the event that no corrosion is detected at the next out-of-service inspection, the calculations will produce a significant increase in the service interval. EEI recommends that the next API internal inspection be scheduled no later than 15 years from the inspection date (2025) or sooner if a change in tank condition has occurred. In the interim, if the tank is removed from service for maintenance cleaning, a limited inspection of the coating should be performed. EEI acknowledges that a 15-year inspection interval exceeds the 10 year interval commonly used by the government but the low corrosion rate supports the longer interval.

An external in-service inspection should be conducted in accordance with API 653 requirements no later than August 2015 (5 years from 2010 inspection), or sooner if a change in condition has occurred.

REPAIR ITEMS

Based upon the API field inspection, engineering judgment, and knowledge of funding practices, recommendations developed are listed below as required (mandatory), recommended (non-mandatory), recommended per military criteria, and recommended for long-term serviceability.

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EEI Project No.: 10-5579

Standard of Care

All repairs shall strictly meet the requirements of API 650 and API 653 regarding material, welding procedures and qualification of welders, non-destructive examination (NDE) of welding and testing requirements. Obtaining hot work permits and developing the appropriate hot work procedure for the tank floor is the responsibility of the repair contractor and shall consider the tank has been in jet fuel service. The provisions of API 2207 “Preparing Tank Bottoms for Hot Work” shall be considered.

Required Repairs Prior to Return to Service (Mandatory)

Mandatory refers to those API 653 items that are considered critical to the hydraulic or structural integrity of the tank or are required to meet code, prior to placing Tank 738 back into service.

The inspection of Tank 738 found no mandatory repairs that would prevent the tank from returning to service.

Recommended Repairs Prior to Return to Service (Non-Mandatory)

The repairs listed below are not mandatory per API 653 or for structural and hydraulic integrity of the tank. EEI highly recommends these repairs for long-term preservation and integrity of the tank and believes that the repairs should be performed while the tank is out of service.

1. The primary (fuel side) seal for the floating pan is the foam log with jacket type. The jacket has been compromised and the foam is retaining product at several sections for a total of approximately 150 feet of circumference. The following repair is recommended:

Provide new solid urethane wiper type seal for the floating pan. Recommend contacting pan manufacturer for recommended style of solid wiper seal.

2. The floating pan wiper seals at the pan penetrations (center column, gauge tubes, ladder leg, anti-rotation cable, etc.) have failed. The following repair is recommended:

Replace the wiper seals at all floating pan penetrations.

3. Reinforcing pads to protect the tank floor from the floating pan legs were set in epoxy mastic. Several of the pads are retaining fuel between the floor and the pad. The following repair is recommended:

Remove breached pads, dry retained fuel, prepare floor coating, and reset the pads using epoxy mastic at original position.

4. The Low Fuel and Water Draw piping in the sump are at 2-1/4 inch and 5 inch elevations from the sump bottom, respectively. The following is recommended:

Extend Water Draw piping to within 1-1/2 inch of the sump bottom so as to be lower than the Low Fuel piping.

5. The tank is equipped with 41 hold down anchors. The nut securing the anchor chair to the anchor bolt is loose at numerous locations. The following repair is recommended:

Tighten the nuts where found loose.

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EEI Project No.: 10-5579

6. Hairline cracks were noted in the concrete ringwall at several hold down anchor locations.

The following action is recommended:

Monitor crack locations during routine inspections.

7. Due to lack of clearance, the anchor bolts have been cut into floor projection at numerous locations. The remaining floor projection does not meet API 650 design criteria. The following action is recommended:

During regular inspections, observe the floor projection at these locations for any change in condition. No repair to standards is deemed compelling or practical.

8. Moss is growing over the sealant between the floor projection (chine) and the concrete ringwall, and it is not clear if the sealant has failed beneath the organic growth. The following repair is recommended:

Remove the moss /organics from the chine sealant.

If the sealant has failed then: remove the sealant, clean the surfaces of the concrete ringwall and the underside the floor to be sealed with an abrasive sweep blast, and provide jet-fuel resistant polysulfide sealant and recoat.

9. The telltale holes at the shell reinforcing plates for the three manways, Fill, Issue, Low Fuel and Water Draw-Off nozzles contain a threaded plug. The following repair is recommended:

Remove the plugs as API criteria require telltale holes to be open to atmosphere. It is recommended (but not required) to pack the holes with general purpose grease to prevent moisture migration between the reinforcing plate and the shell.

10. The stainless steel pilot tubing for the high level shutoff control valve is routed such that contact is made at the wind girder and high level float nozzles. Vibration of the tubing may cause abrasion resulting in failure of the tubing. The following repair is recommended:

Provide Teflon sheet shields wrapped around the tubing to eliminate metal to metal contact between the tubing and the tank appurtenances.

11. The water draw-off nozzle includes a 2” angle pattern non-freeze valve. The following repair is recommended:

Replace the valve with a 2” double-block and bleed plug valve.

12. The tank is equipped with six perimeter roof vents. The hold down latches on the roof vents have failed at numerous locations. The following repair is recommended:

Replace the latches on all of the roof vents.

13. The grounding cable connecting the roof manway cover to the roof plate has been severed.

The following repair is recommended:

Replace the grounding connection between the roof manway and roof plate.

14. Water ponding was observed on several of the perimeter roof plates and at weld seams. This condition may cause coating failure and corrosion. The following is recommended:

Monitor ponding locations during routine inspections.

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EEI Project No.: 10-5579

15. Localized coating failure and minor corrosion were observed on the interior floor plates, interior manway nozzles, interior shell, shell valves, anchor bolts and chairs, the floor projection at the CP connections, stairs, landings, roof appurtenances and perimeter roof handrail posts.

Remove the existing coating from the affected areas, clean and recoat.

16. Provide surface preparation and recoat all repair areas and areas damaged as a result of repairs in accordance with Coating Requirements.

17. New item added after Field Trip Report was issued. This can be repaired at next out-of-service inspection. The body cavity relief (BCR) on the 12 inch Issue DB&B, 10 inch Receipt DB&B and 6 inch Low Fuel line DB&B are piped to the tank side of the valve body.

The following is recommended:

Re-pipe BCRs to pipeline side of valve body.

Recommended Repairs per Current Military Criteria

The following recommended repairs are in accordance with UFC 3-460-1:

Table 8-1 of UFC 3-460-01 (July 2008 issue pending) describes appurtenances for vertical aboveground storage tanks.

1. The tank is not equipped with item (c) a manway located above the internal floating pan’s high position to aid in venting and provide access to area above floating pan. The following is noted:

The area above the floating pan can be accessed from the roof manway or from the manway in the floating pan. The tank can be vented by the three manways below the floating pan and the one manway in the roof. No other action is required.

2. The tank is not equipped with item (e) four 24 inch square inspection hatches. The tank is equipped with one 41 inch x 77 inch roof hatch, and one 36 inch diameter manway with ladder and perimeter roof scoops. The following is noted:

The purpose of the hatches is to allow inspection of a floating pan and a floating pan seal.

The 36 inch manway with ladder and perimeter roof scoops serve this function, no other action is required.

3. The tank is not equipped with item (r) one 8 inch gauge hatch for water bottom sampling as close to the center as possible. The following is noted:

Refer to “Gauge Tubes’ for additional discussion.

4. The tank is not equipped with item (s) one 8 inch gauge hatch with aluminum, slotted stilling well extended to within 3 inches of the bottom of the lowest point in the tank for gauging and sampling. The following is noted:

Refer to “Gauge Tubes’ for additional discussion.

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EEI Project No.: 10-5579

Recommended Repairs for Long Term Serviceability

1. Program the tank for an API external in-service inspection in 5 years (2015) and an API out-of-service internal inspection no later than 15 years (2025).

2. Recommend floor coating inspection at each Air Force out-of-service fuel quality inspection to determine if full re-coat is required.

3. Recommend double foam wiper seal inspection at each Air Force out-of-service fuel quality inspection to determine if replacement is required.

4. Test all level alarms and switches as part of on-going maintenance.

COATING REQUIREMENTS

All repairs involving steel surface grinding, cutting, and welding shall be preceded by proper coating removal. At this time, it is not known if any of the existing coating layers have significant lead or chromate components. It is extremely unlikely due to the age of the tank. The contractor shall be responsible for testing coating systems for lead and chromate levels and develop engineered controls to prevent worker safety hazards and spread of contaminated dusts.

Coating removal method shall be contractor determined to suit contamination levels and follow-up steps.

Coating System at Localized Repair Locations (Interior and Exterior)

Provide repair of localized areas of failed and damaged coating on the interior and exterior of the tank and areas affected by the contractor’s work. Provide a coating system that complies with MIL-PRF-4556F (superseding MIL-C-4556), two-coat application, 4 to 8 mils DFT per coat.

Provide surface preparation in accordance with the coating manufacturer’s recommendations to ensure adhesion of the coating system. For tank interior coating, provide surface preparation in accordance with the coating manufacturer’s recommendations for immersion service. Provide 2 to 3 mil surface profile unless recommended otherwise by the coating manufacturer. Prior to surface preparation, test surfaces for soluble salts, oil, and grease and clean as required to remove contaminants. Tank interior coatings shall cure for not less than 14 days prior to introducing fuel into the tank. Provide longer cure time when recommended by the coating manufacturer.

As an alternative for interior repairs, use the 3 coat MIL-DTL-24441 epoxy polyamide system as specified in Unified Facilities Guide Specifications (UFGS) section 09 97 13.17, Interior Coating of Petroleum Storage Tanks. As an alternative for exterior repairs, use the 2 coat MIL-DTL- 24441 epoxy polyamide system with polyurethane topcoat as specified in UFGS section 09 97 13.27, Exterior Coating of Steel Structures.

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EEI Project No.: 10-5579

SUITABILITY FOR SERVICE EVALUATION

Corrosion Rates

Corrosion rates of the tank floor, shell, and roof were calculated using nominal metal thicknesses when the tank was constructed in 1998 and the plate thicknesses that were obtained from UT measurements at the time of the inspection. The corrosion rates are summarized as follows:

Floor: 0.005250 inches per year (assumed 20% metal loss not detected by MFL)

Shell: Negligible – Plate thickness is within mill tolerance.

Roof: Negligible – Plate thickness is within mill tolerance.

Tank Floor Corrosion Rates

The tank floor coating, with an average thickness of 16.3 mils, is a thin-film lining. For tanks with coated floors, API 653 permits a product side corrosion rate (StPr) of 0.00 in/yr. The floor coating is 12 years old. Although it is in generally good condition, a number of coating anomalies were observed and are recommended for repair. No actual pits were identified in the floor during the inspection.

Bottom side corrosion with small volumetric metal loss may be present and not detected by MFL scanning. The metal loss used to establish the bottom side corrosion rate was conservatively calculated using the average thickness of the floor minus a 20% threshold value for undetected bottom side pits per API. The MFL floor scanner is not setup to indicate (alarm) for minor metal loss.

The minimum remaining floor thickness (MRT) used in the calculations is based on API 653 Section 4.4.5.3 and Table 4.4. Tank 738 is equipped with the means to detect and contain a bottom leak. The tank is equipped with four leak detection pipes. A review of the design drawings confirmed the presence of a liner beneath the sand cushion. Based on this information, the MRT used in the calculations is 0.050 inch.

It was found that the floor plate thickness will not be reduced below the limiting MRT at a 15-year inspection interval.

Hydraulic and Structural Integrity

The following table summarizes the hydraulic and structural integrity of Tank 738:

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item

Findings Comments

Foundation Tank 738 rests on a concrete ringwall. The tank passes API 653 criteria for levelness and differential settlement.

Acceptable

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EEI Project No.: 10-5579

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item

Findings Comments

Floor Visual inspection of the floor joints found no relevant indications. MFL scanning of the tank floor found no relevant indications of corrosion on the bottom side of the floor. A pit survey was conducted for topside corrosion and no areas were identified for repair.

Based upon the calculated corrosion rate, the floor plate thickness will not be reduced below the minimum floor plate thickness of 0.050 inches at a 20 year inspection interval.

Acceptable

Shell Inspection found no indication of damage or deterioration to the shell.

Acceptable

Roof Inspection found no indications of damage or deterioration to the roof.

Acceptable

Internal Fluid Pressure

Hoop stresses caused by internal fluid pressure pass API 653 criteria.

Acceptable

Hydrostatic Test

Shell is adequate to resist the internal fluid pressure caused by a full height hydrostatic test with water.

Acceptable

Brittle Fracture The API 653, Section 5, Figure 5.1, Brittle Fracture Considerations has been evaluated with the following findings:

1. Does the tank meet API 650 (7th edition, 1980, or later): Yes, constructed in 1998.

2. Has a prior hydrotest been performed demonstrating fitness: Yes.

3. Is the tank shell thickness < 0.5”: Yes.

4. Does the tank operate at a metal temperature above 60° F: No.

5. Membrane stress below 7 ksi: No.

6. Tank steel exempt per API 650, Figure 4-1 or API 653 Figure 5.2: Yes.

7. Tank full at lowest one day temperature per API 650 Figure 2.2: Unknown.

The tank, having been built in 1998 and shell thickness less than 0.5 inch thick, does not fit the API profile for brittle fracture risk.

Seismic Seismic calculations were performed in accordance with API 650 Appendix E. It was found that the tank is not at risk of overturning and the compressive stresses are within limits at the current maximum fill height of 47 feet 6 inches.

Calculations were performed utilizing the specific gravity for JP-8 (S.G.=0.82), a concrete ringwall foundation, seismic parameters Ss=1.49, S1=0.55 and an importance factor of 1.0.

Acceptable

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EEI Project No.: 10-5579

HYDRAULIC AND STRUCTURAL INTEGRITY

Evaluation Item

Findings Comments

Wind Evaluation

A wind analysis was performed per API 650, Section 5.11.

Calculations were performed using an importance factor of 1.0 and a wind velocity of 100 mph. It was found that the tank is not at risk of overturning or slide while empty.

Evaluation of the shell buckling determined that the shell is adequate, without stiffeners, for wind speeds in excess of 100 mph.

Acceptable

ADDITIONAL DISCUSSION ITEMS

Gauge Tube Requirements

The requirements for stilling wells have been reviewed. These requirements are based on the DESC Memorandum “Automated Tank Gauge (ATG) Installation Policy” of December 2009.

The comments below represent concept solutions based on the memorandum. It is recommended that the concept be submitted to DESC for ratification or redirection. Field verification of constructability by the prime contractor is also recommended.

Tank 738 Existing Conditions

The tank is an AST with a cone-down floor and includes a center sump. The roof is fixed with a center roof support column. The tank is equipped with two gauge tubes. An 8 inch thief hatch and 8 inch full height slotted gauge tube for manual gauging is present in the roof manway cover plate which is located near the tank shell. The sensor for the ITT Barton ATG is located near the tank shell in a 10 inch hatch and 8 inch partial height slotted tube.

Gauge Tube Recommendation

The following are recommended for compliance with the DESC/DLA Memorandum (for ATG) and UFC 3-460-01 (for operations):

1. The existing 8 inch aluminum gauge for ATG is only partially slotted. If full compliance to UFC criteria is required, then it is recommended that the slotting be extended to full height of gauge tube.

2. Provide an 8 inch aluminum gauge tube for the temperature/water probe (DLA directive for future ATG retrofit). The gauge tube should be located over the existing tank sump. If an 8 inch gauge tube located over the sump cannot be accommodated due to roof framing configuration, a 6 inch tube may be used. The roof support structure collocated vertically over the sump may make gauge tube installation not possible or not practical.

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EEI Project No.: 10-5579

CLOSURE

Conclusions

Based on the extent of this inspection and completion of the mandatory repairs, Tank 738 is considered suitable for service.

Project Team

Site Team

Ali M. Martinez, P.E. Mechanical Engineer, API 653 Aboveground Storage Tank Inspector Certificate No. 28604, API Inspector of Record.

Adam W. Ludemann, E.I.T. Mechanical Engineer

Travis W. Snyder, E.I.T. Mechanical Engineer

Support Team

Stacy M. Kaplan-McMillan Project Manager

Stephen S. Brooks, P.E. Technical Advisor, QA Review, API 653 Aboveground Storage Tank Inspector Certificate No. 17

APPENDIX A

Tank Inspection Data Sheet and Checklist

APPENDIX A AST Tank Inspection Data Sheet Tank 738 – API 653 Inspection September 2010 EEI Project No.: 10-5579

DLA ENERGY TANK CMP CONDITION FORM

TANK INSPECTION SUMMARY SHEET

Tank Location Elmendorf AFB, Alaska Facility Number 18471

Tank No. 738 Inspection Date(s): August 17 and 18, 2010

Tank Type: Vertical AST Type of Inspection: Internal & External w/ Suitability for Service

Prime Contractor Name: Winsor Construction, Inc.

Inspector, Certificate #: Ali M. Martinez, P.E.

ANSI/API 653 AST Inspector Certificate No. 28604

Inspection Company: Enterprise Engineering, Inc.

2525 Gambell Street, Suite 200 Anchorage, AK 99503

(907) 563-3835

Manufacturer, Date, Design Standard Morse Construction Group, 1998, API 650 9th Edition, Appendices A, E & H

Diameter: 112'-0" Shell Height: 51'-6"

Product, Specific Gravity: JP-8, 0.82 Design Pressure / Temperature: Atmospheric / -15 Deg. F. Design Metal Temperature

Gross Capacity / Nominal Capacity: 83,286 BBLS / 80,000 BBLS Safe Fill Height: 47’–6” (Tank Nameplate), 41’-9” (Stenciled on Tank)

GPS Latitude & Longitude: 61 Deg 15’ 47.41” N, 149 Deg 48’ 46.44” E (Source – Google Earth)

Foundation Configuration: Concrete Ringwall Shell Configuration: Butt Welded w/ 7 courses Floor Configuration: Cone down w/ lap welded plates oriented in rows

Roof: Fixed cone Cathodic Protection: Present

Still Wells: Yes (Add’l information enclosed) Last Inspection (Type, Date): External August 2005

Last Coated Internally (Product): Original coating Last Coated Externally (Product): Original coating

INSPECTION RESULTS

Can tank be returned to service? Yes, repairs recommended.

Deficiencies identified as mandatory repairs: No. (See paragraph titled “Repair Items” in body of report)

Deficiencies identified as recommended repairs:

Yes. (See paragraph titled “Repair Items” in body of report)

Deficiencies identified as long term repairs: Yes. (See paragraph titled “Repair Items” in body of report) Next Scheduled Inspections (Type, Date:) Out-of-Service: August 2025 (15 Years)

In-Service: August 2015 (5Years)

ADDITIONAL ITEMS

Change in Service: None As-Built Drawings, Specifications: Design drawings available

APPENDIX A AST Evaluation Items - TOC Tank 738 – API 653 Inspection September 2010 EEI Project No.: 10-5579

AST EVALUATION ITEMS

TABLE OF CONTENTS

PAGE

FOUNDATION

FLOOR

SHELL

ROOF

INTERNAL FLOATING PAN

COATINGS

APPURTENANCES

PIPING

APPENDIX A - AST Evaluation Items Page 1 Tank 738 – API 653 Inspection September 2010

FOUNDATION

Evaluation Item Finding(s) Comments/Recommendations (A blank in comments column indicates lack of significance, or condition is acceptable.)

FOUNDATION

Type The tank rests on a concrete ringwall.

The ringwall is in good condition.

Minor cracking observed at several anchor locations.

Recommend monitoring cracks during routine inspections.

Levelness The differential between maximum and minimum elevations is 0.04 feet (0.48 inches).

The tank passes API 653 criteria for shell levelness and differential settlement.

Rigid Body Tilt The tank has a small amount of tilt.

The amount of tilt is 0.02 feet (0.22 inches).

The tank passes API 653 criteria for rigid body tilt.

Height Above Dike Floor The top of the concrete ringwall is approximately 10 inches above the adjacent dike floor.

Material Below Tank Floor Design drawings indicate sand cushion with secondary containment liner. Four leak detection ports are located equidistant around the perimeter of the tank.

Drainage Around Tank Minor ponding is present at several locations around the tank. Drainage around the tank appears to be adequate.

Tank Anchors The tank has 41 anchors equidistant along tank perimeter. The anchor bolts have a diameter of 1-5/8”.

The nut securing the anchor chair to the bolt is loose at several locations.

Anchor bolts have been cut into floor projection at numerous locations. The reaming floor projection does not meet API 650 design criteria.

Calculations indicate that the tank is stable and not subject to overturning or sliding due to wind or seismic forces.

Recommend tightening bolts.

Recommend monitoring for change in condition during routine inspections.

Containment Dike The tank sits within a containment dike.

Secondary Containment The tank is in an earthen dike with a membrane liner attached to the ringwall with a SS batten strip. The liner has gravel ballast.

Settlement Calculations indicate that the tank passes AAPI 653 criteria for settlement.

Erosion/Washouts No indications of washouts or erosion were observed.

APPENDIX A - AST Evaluation Items Page 2 Tank 738 – API 653 Inspection September 2010

FOUNDATION

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Sealed at Foundation The exterior floor projection is sealed to the concrete ringwall with an elastomeric sealant. The sealant has separated from the floor projection at numerous locations. Moss is growing at several locations.

Recommend removal of moss and vegetation. Remove sealant that has failed. Re-seal floor extension to ringwall with jet fuel resistant polysulfide sealant.

Additional Foundation Items, Comments or Notes:

None.

APPENDIX A - AST Evaluation Items Page 3 Tank 738 – API 653 Inspection September 2010

FLOOR

(A blank in comments column indicates lack of significance, or condition is acceptable.)

TANK FLOOR

Type The tank floor configuration is cone down with lap welded steel plates oriented in rows.

Nominal Thickness Floor plates are 5/16 inch (0.3125 inch) thick nominal.

Annular Ring Plates The tank is not equipped with an annular ring.

Floor Projection (Chine) Floor project extends an average of 2- 1/2” from shell.

Thickness The average thickness of the interior floor plates based on 5 UT readings per floor plate is 0.315 inches.

Interior Width The average floor plate width is 8 feet.

Floor seam welds Visual inspection of the floor seam welds found no relevant indications requiring further inspection.

MFL Floor Scan MFL of the accessible areas of the floor found no indications requiring an UT prove-up.

Bottom Side Floor Pitting/Corrosion

Based on MFL and UT examination, bottom side pitting/corrosion is not prevalent.

Top Side Floor Pitting/Corrosion

The floor is coated. No pitting was observed.

Doubler/Support Plates The center column base structure rests on an 8’ square support plate seal welded to the floor.

There is a 6” diameter support plate seal welded to the sump under the 1- 1/2” water draw off line.

There is a 24” diameter support plate seal welded to the floor beneath the 8” diameter slotted gauge tube.

There are 6” and 24” diameter support plates beneath the legs of the roof access ladder/gauge tube.

There are 12” x 12” stainless steel reinforcing pads set in epoxy mastic to the floor beneath each floating pan leg.

Several of the pads are retaining fuel between the floor and pad.

Recommend removal of breached pads, dry, prepare floor coating and reset pads using epoxy mastic.

APPENDIX A - AST Evaluation Items Page 4 Tank 738 – API 653 Inspection September 2010

(A blank in comments column indicates lack of significance, or condition is acceptable.)

Patch Plates None present.

Plug Welds No plug welds were observed.

Weld Artifacts No weld artifacts were noted.

Vacuum Box Testing The floor weld seams are coated.

Vacuum box testing was not performed.

Helium Leak Testing HLT was not performed.

Floor Bulges, Depressions No significant bulges or depressions were noted.

Oil Canning/Flexing No significant flexing of floor plates was

Edge Settlement Edge Settlement was not noted.

Measurements taken for edge settlement.

The tank passes API 653, Appendix B criteria.

Floor Critical Zone No significant corrosion or deflection was observed within the critical zone.

Floor Profile The floor is sloped with one center sump.

Sumps The tank has one 41 inch diameter center sump that is 10-1/2 inches deep.

The sump contains the 1-1/2 inch water draw-off and 6 inch low fuel pipes. The 12 inch issue pipe is above the sump.

The low fuel and water draw piping in the sump are at 2-1/4 inch and 5 inch elevations from the sump bottom, respectively.

UT thickness readings of the sump wall plate averaged 0.488 inches and the sump bottom plate averaged 0.483inches.

Recommend extending the water draw-off piping to within 1-1/2 inches of the sump bottom.

Secondary Liner Below Floor The design drawings indicate that there is a secondary liner below the tank floor.

Leak Detection Below Floor Two 6 inch diameter standpipes on opposite sides of the tank. Water with slight sheen visible upon opening of thief hatches; however no petroleum odor was observed.

Recommend the standpipes be monitored during routine inspections.

Cathodic Protection Below Floor

The tank floor is protected by an impressed current cathodic protection system.

APPENDIX A - AST Evaluation Items Page 5 Tank 738 – API 653 Inspection September 2010

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Additional Floor Items, Comments, Notes:

None. See coating discussions later in evaluation items.

APPENDIX A - AST Evaluation Items Page 6 Tank 738 – API 653 Inspection September 2010

SHELL

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TANK SHELL

Nominal Thickness UT Thickness Coating

1st Course 0.625 inch 16.2 mils Material: A516 Grade 60

2nd Course 0.556 inch 14.9 mils Material: A516 Grade 60

3rd Course 0.473 inch 13.7 mils Material: A516 Grade 60

4th Course 0.311 inch 17.1 mils Material: A516 Grade 60

5th Course 0.253 inch 24.8 mils Material: A516 Grade 60

6th Course 0.246 inch 13.4 mils Material: A516 Grade 60

7th Course 0.259 inch 15.7 mils Material: A516 Grade 60

Plumbness Visual observations found no noticeable out-of-plumbness.

Roundness The tank was measured across two diagonal locations with no out-of-roundness noted.

Dents/Buckles No significant dents or buckles requiring repairs were observed.

Banding/Peaking No significant banding or peaking was

Interior Shell pitting/corrosion No pits or corrosion were observed on the interior 1st shell course. The upper courses of the interior shell were not accessible.

Exterior Shell pitting/corrosion No significant pits or corrosion were observed on the exterior shell as viewed from the ground elevation.

Insert plates None present.

Door sheet None present.

Welded Patch Plates No welded patch plates were observed on the exterior or interior shell surfaces.

Interior Shell Welds Visual inspection of accessible interior shell welds found no indications for further inspections or examinations.

Exterior Shell Welds Visual inspection of accessible exterior shell welds found no indications for

Shell-to Floor Weld – Interior Visual inspection of the interior shell-to-bottom welds found no indications for

APPENDIX A - AST Evaluation Items Page 7 Tank 738 – API 653 Inspection September 2010

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Shell-to Floor Weld – Exterior Visual inspection of the exterior shell-to-floor welds found no indications for

Shell Manways First course shell has three 36 inch” diameter manways.

Flush Cleanouts The tank is not equipped with a flush cleanout.

Shell Reinforcing Plates

Manway #1

(Size, Thickness, Telltale Hole)

36 inch diameter nozzle, 0.628 inch thick neck (UT).

Tombstone reinforcing plate 78.25 inches wide x 78 inches tall x 0.636 inches thick (UT).

Cover plate thickness is 0.907 inch.

A threaded plug is present in the telltale hole on the reinforcing plate.

The reinforcing plate does not meet current API 650 criteria for open telltale holes.

Recommend removing the plug and packing the hole with grease to prevent moisture migration.

Manway #2

(Size, Thickness, Telltale Hole)

36 inch diameter nozzle, 0.633 inch thick neck (UT).

Tombstone reinforcing plate 78 inches wide x 80 inches tall x 0.632 inches thick (UT).

A threaded plug is present in the telltale hole on the reinforcing plate.

The reinforcing plate does not meet moisture migration.

Manway #3

(Size, Thickness, Telltale Hole)

36 inch diameter nozzle, 0.625 inch thick neck (UT).

Tombstone reinforcing plate 78 inches wide x 80 inches tall x 0.631 inches thick (UT).

Cover plate thickness is 0.808 inches.

A threaded plug is present in the telltale hole on the reinforcing plate.

The reinforcing plate does not meet moisture migration.

Receipt/Fill

(Size, Thickness, Telltale Hole)

10” diameter nozzle, 0.503 inch thick neck (UT).

Circular reinforcing plate 24 inch diameter x 0.630 inch thick (UT).

A threaded plug is present in the telltale hole on the reinforcing plate.

The reinforcing plate does not meet moisture migration.

APPENDIX A - AST Evaluation Items Page 8 Tank 738 – API 653 Inspection September 2010

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Issue

(Size, Thickness, Telltale Hole)

12 inch diameter nozzle, 0.484 inch thick neck (UT).

Circular reinforcing plate 28 inch diameter x 0.630 inch thick (UT).

A threaded plug is present in the telltale hole on the reinforcing plate.

The reinforcing plate does not meet moisture migration.

Water Draw-Off

(Size, Thickness, Telltale Hole)

3 inch diameter nozzle, 0.303 inch thick neck (UT).

Tombstone reinforcing plate 10-1/2 inches wide x 13 inches tall x 0.630 inch thick (UT).

A threaded plug is present in the telltale hole on the reinforcing plate.

The reinforcing plate does not meet moisture migration.

Low Fuel Draw-Off

(Size, Thickness, Telltale Hole)

6 inch diameter nozzle, 0.437 inch thick neck (UT).

Circular reinforcing plate 15-1/2 inch diameter x 0.630 inch thick (UT).

Telltale hole is present with a threaded plug.

The reinforcing plate does not meet moisture migration.

Fire

(Size, Thickness, Telltale Hole)

The tank is not equipped with a fire/foam nozzle.

Shell Vents The tank is not equipped with shell vents.

Overflow Ports The tank is equipped with six overflow ports. Opening size is 25-1/2 x 19 inches and hood size is 30 x 24 inches.

Wind Girders and Shell Stiffeners (Size & Elevation)

The tank is equipped with circumferential wind girder and vertical shell stiffeners. The wind girder is constructed of bent plate with a horizontal leg varying from 9” to 18” wide and a vertical leg 5” tall. The wind girder is located 13’-10” down from the roof edge. The vertical shell stiffeners (24 total, 8 groups of 3) are constructed of 6” x 6-1/2” tees and extend 9’-1” down from roof edge.

APPENDIX A - AST Evaluation Items Page 9 Tank 738 – API 653 Inspection September 2010

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Tank Nameplate Data:

Tank Manufacturer: Morse Construction Group Inc.

Morse Serial No.: 2339-01-EL-6066

Year Built: 1998

Standard of Construction: API 650 9th Edition

Tank Diameter: 112’-0”

Tank Shell Height: 51’-6”

Design Capacity: 83,286 BBLS

Normal Fill Height: 47’-6”

Stored Product: JP-8

Specific Gravity: 0.87

Pressure: Atmospheric

Operating Temperature: -15 deg F DMT

Partial Stress Relief: No

Shell Courses 1-7: A516 Gr 60

Additional Shell Items, Comment or Notes:

The following is stenciled on the tank shell adjacent to the tape gauge: SAFE FILL 41’-9”

APPENDIX A - AST Evaluation Items Page 10 Tank 738 – API 653 Inspection September 2010

ROOF

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TANK ROOF

Type Fixed cone up with one 18” diameter center roof support column.

Roof Plate Thickness The roof consists of 1/4 inch (0.25 inch) thick roof plates. Average thickness for the roof plates is 0.246 inch.

Roof Topside Pitting/Corrosion No significant pitting or corrosion was identified on the topside of the roof.

See “Roof Exterior” under Coatings section.

Roof Topside Condition No significant bulges or depressions were identified.

Water ponding was observed on several perimeter roof plates and weld seams.

Recommend monitoring during routine inspections.

Roof Welds Roof plates are lap welded on the exterior of the roof. Visual inspection of topside roof welds found no relevant indications for further inspection or examination.

Frangible Joint (Size/Condition) ¼ inch roof plates, fillet welded to 3 inch rim angle with a 3/16 inch joint.

The roof connection at the shell meets the definition of a frangible joint for emergency venting.

Roof Vents (Size & Type) The tank has a single center 26 inch atmospheric nozzle with a 48 inch diameter dome cover and bird screen.

The tank has six perimeter roof vents.

The hold down latches have failed at numerous locations.

No pressure/vacuum vents are installed.

Recommend replacing the latches on all of the roof vents.

Roof Manways The roof has a 36 inch diameter manway with an 8 inch diameter thief hatch.

The grounding cable connecting the manway to the roof plate is severed.

Recommend replacing ground connection.

Roof Hatches The tank is equipped with a 36 inch x 72 inch construction hatch.

APPENDIX A - AST Evaluation Items Page 11 Tank 738 – API 653 Inspection September 2010

ROOF

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Roof Nozzles (3) 1-1/2 inch diameter nozzles for tape gauge system.

(1) 10” nozzle with thief hatch for ATG system.

(1) 8” thief hatch for manual gauging located on 36” manway.

(3) 3” diameter nozzles for floating pan grounding cables.

(1) 3” nozzle for the floating pan anti-rotation guide cable.

Handrails Handrail with kick plate provided at perimeter of tank. Visual examination found no significant structural problems.

Roof Access from Ground Roof access is by spiral staircase.

Roof Access to Adjacent Tank None.

Roof Framing / Roof Underside Condition

The interior roof structure appears to be in good condition with no twisting or bending of components. The interior roof framing was evaluated visually from the floating pan with no indications for further examination.

Roof Elevation The center of the cone roof is raised above the shell elevation.

Interior Columns There is one 18” center pipe column with base support structure.

SEE TANK APPURTENANCES FOR ATG, GAUGING, LEVEL ALARMS, ETC.

Additional Roof Items, Comments or Notes:

APPENDIX A - AST Evaluation Items Page 12 Tank 738 – API 653 Inspection September 2010

INTERNAL FLOATING PAN

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FLOATING PAN

Material Type Aluminum honeycomb configuration.

Primary Seal Type Foam filled wiper seal. The jacket has been compromised and the foam is retaining product for approximately 150 linear feet along the circumference.

Recommend providing new solid urethane wiper seal.

Secondary Seal Type Foam filled wiper seal. Acceptable condition.

Long term life suspect. Review at every Air Force inspection to determine need for replacement. Recommend solid urethane wiper, not foam filled jacketed wiper seal.

Vacuum Breaker/Pressure Relief The floating pan has a single pressure/ vacuum vent.

Roof Access – Ladder to roof There is an internal ladder that can be accessed through the roof manway.

Leg Supports The floating roof is equipped with 14 aluminum legs and stainless steel striker plates. The striker plates are sealed to floor with mastic.

Anti-Rotation Method The floating roof is equipped with one anti-rotation cable extending from roof to floor.

Roof Grounding There are 3 grounding cables.

Appurtenance Seals The floating pan wiper seals at the center column, combination ladder/gauge tube, anti-rotation cable, etc. have deteriorated.

Recommend replacing the seals.

Additional Floating Roof Items, Comments or Notes:

APPENDIX A - AST Evaluation Items Page 13 Tank 738 – API 653 Inspection September 2010

COATINGS

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Exterior Coatings

Shell

Type/age Epoxy polyamide with polyurethane topcoat coating system. Original coating 1998.

General Condition In general, the coating is in good condition with good adherence.

Isolated Conditions Localized coating failure was observed on the shell appurtenances.

Recommend removing the coating from the affected areas, clean and recoat.

Nominal Thickness The average thickness of the shell coating for all seven courses is 16.5 mils. The maximum thickness is 30.0 mils and the minimum thickness is 8.4 mils.

Lead and Chromate Testing Not performed. Presence is unlikely given the age of the tank.

Roof

Type/age Epoxy polyamide with polyurethane topcoat coating system. Original coating 1998.

on the roof appurtenances.

Recommend removing the coating from the affected areas, clean and recoat.

Nominal Thickness The average thickness of the roof coating is 15.1 mils. The maximum thickness is 22.3 mils and the minimum thickness is 11.3 mils.

Interior Coatings

Floor

Type/age Epoxy polyamide coating system.

Original coating 1998.

General Condition The interior floor coating system is in good condition.

on the roof appurtenances.

Recommend removing the coating from the affected areas, clean and recoat.

APPENDIX A - AST Evaluation Items Page 14 Tank 738 – API 653 Inspection September 2010

COATINGS

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Nominal Thickness The average thickness of the coating is

16.3 mils; with a maximum thickness of

27.6 mils and a minimum thickness of

16.3 mils.

Shell

Condition at Floor to Shell Coating at the floor-to-shell joint is in good condition.

on the interior manway nozzles and shell

Recommend removing the coating from the affected areas, clean and recoat.

Nominal Thickness The average thickness of the 1st course coating is 16.0 mils; with a maximum thickness of 28.1 mils and a minimum thickness of 16.0 mils.

Underside Roof

Isolated Conditions No isolated conditions noted.

Nominal Thickness Not measured.

Additional Coating Items, Comment or Notes:

APPENDIX A - AST Evaluation Items Page 15 Tank 738 – API 653 Inspection September 2010

APPURTENANCES

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APPURTENANCES

Float Gauge The tank is equipped with a Varec tape gauge.

ATG (Automatic Tank Gauging) or RTG (Remote Tank Gauging) System

An ITT Barton ATG system is used for automatic gauging. Reference Point 53’-6” is stenciled to ATG nozzle on roof.

HI/HI-HI Level Alarms The HI/HI-level and HI-level sensors are mounted at 98% and 95% fill heights respectively.

Low Level Alarms The LOW-level sensor is mounted at 36” liquid level.

Independent Level Alarms The tank is equipped with an independent level alarm, see ATG System.

Temperature Probe A shell side manual temperature gauge and probe is not present, and is no longer a requirement.

Gauge Tube – ATG A 10” diameter thief hatch and partially slotted 8” gauge tube is present for the ITT Barton ATG on the roof.

If full compliance to UFC criteria is required, then it is recommended that the slotting be extended to full height of gauge tube.

Gauge Tube – Sampling/Testing/Hand Gauging

Manual gauge tube and ladder leg combination. The 8” gauge tube is slotted full height.

Datum Plate on Floor The two gauge tubes have datum plates seal welded to the floor beneath them.

Cathodic Protection Impressed current cathodic protection system.

Tank Grounding The tank has four static grounding cables attached to the shell.

Fire Suppression System The…